New Process for Producing Humic Acid Salts with Fluidizing Solid Phase Reaction

ABSTRACT

The present invention utilizes a high-speed intensive mixer in a fluidizing-type, solid-phase, neutralization reactor to blend solid-state alkali hydroxide with any humic acid sources. The final product is a dry humic acid salt. The purpose of this innovative method is to eliminate a series of complicated unit operations commonly employed by the traditional process. These removed steps may include dissolving caustic soda, mixing in a paste-like formation, extrusion, granulation, drying, and grinding, etc. The invention contributes to a simplified flowsheet, resulting in sharply reduced equipment investment, plant space, and labor and energy costs. All of these factors coupled with increased productivity will drastically lower the overall production cost. Also, the reduction of dust pollution will greatly minimize the impact in environmental protection and safety issues.

CROSS-REFERENCE TO RELATED APPLICATIONS

This is a continuation of application Ser. No. 15/731,032 filed on Apr. 10, 2017; which claims priority under 35 U.S.C. § 119(e) to U.S. Provisional Application No. 62/331,788 filed on May 4, 2016; the entire contents of both applications are hereby incorporated by reference.

BACKGROUND AND SUMMARY OF THE INVENTION

Traditional methods for production of humic acid salts involve complicated unit operations that are costly and usually cause serious environmental issues. This invention uses a high-speed intensive mixer to promote chemical reaction between alkali hydroxide (including potassium hydroxide, sodium hydroxide, or ammonium hydroxide solution, etc.) and any substances containing humic acid. The new process quickly makes a dry product in a solid-phase, fluidized-bed type reactor and can replace the traditional manufacturing procedure with significantly higher efficiency and cost benefits. It also addresses the common public concerns on the safety and pollution problems.

This invention uses only a high-speed intensive mixer to produce the same final products by a single step, completing any of following chemical reactions:

R—COOH+NaOH→R—COONa+H₂O

R—COOH+KOH→R—COOK+H₂O

R—COOH+NH₄OH→R—COONH₄+H₂O

The basic principle of the present invention is different from the traditional fluidized bed. The present invention only utilizes high-speed agitation, instead of large amounts of gas, to fluidize solid powder. In practice, one or more alkali hydroxide (including potassium hydroxide, sodium hydroxide, or ammonium hydroxide solution, etc.) can be added to react with any humic acid source.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a flow chart of a caustic humate manufacturing process by solid-phase reaction.

FIG. 2 is a flow chart of a potassium humate manufacturing process by solid-phase reaction.

FIG. 3 is a flow chart of a sodium humate manufacturing process by solid-phase reaction.

FIG. 4 is a flow chart of an ammonium humate manufacturing process by solid-phase reaction.

DETAILED DESCRIPTION OF THE INVENTION

Typical flow charts of the above reactions can be shown in FIGS. 1 to 4 in which the major pieces of equipment are numerically marked and identified as follows:

-   -   (1) Unloading hopper,     -   (2) Pneumatic conveyer,     -   (3) Premixing feed tank,     -   (4) Automatic weighing machine,     -   (5) Solid-phase reactor,     -   (6) Intermediate tank,     -   (7) Cyclone separator,     -   (8) Dust collector,     -   (9) Storage tank,     -   (10) Bagging machine,     -   (11) Blower,     -   (12) Ammonium hydroxide feeding tank,     -   (13) Dust collector, and     -   (14) Seal box.

FIG. 1 shows a flow chart of a caustic humate manufacturing process by solid-phase reaction. The process includes the steps below:

1. Feed humic acid to a mixer (3) by pneumatic conveyor (2) to premix the humic acid thoroughly.

2. Feed a fixed amount of the premixed humic acid into the solid-phase reactor (5) to agitate with a high-speed mixer.

3. Slowly add the solid-state alkali hydroxide into the mixer (5) at a given rate.

4. Continue the high-speed agitation while proceed to complete mixing, reaction, and drying.

5. Unload the produced caustic humate salt into the intermediate tank (6) for cooling down, then transfer it to a storage tank (9) by pneumatic conveyor.

FIG. 2 is a flow chart of a potassium humate manufacturing process by solid-phase reaction. The process includes the steps below:

1. Feed humic acid to a mixer (3) by pneumatic conveyor (2) to premix the humic acid thoroughly.

2. Feed a fixed amount of the premixed humic acid into the solid-phase reactor (5) to agitate with a high-speed mixer.

3. Slowly add the solid-state potassium hydroxide into the mixer (5) at a given rate.

4. Continue the high-speed agitation while proceed to complete mixing, reaction, and drying.

5. Unload the produced potassium humate salt into the intermediate tank (6) to cool down, then transfer to a storage tank (9) by pneumatic conveyor.

FIG. 3 presents a flow chart of a sodium humate manufacturing process by solid-phase reaction. The process includes the steps below:

1. Feed humic acid to a mixer (3) by pneumatic conveyor (2) to premix the humic acid thoroughly.

2. Feed a fixed amount of the premixed humic acid into the solid-phase reactor (5) to agitate with a high-speed mixer.

3. Slowly add the solid-state sodium hydroxide into the mixer (5) at a given rate.

4. Continue high speed agitation while proceed to complete mixing, reaction, and drying.

5. Unload sodium humate salt produced into intermediate tank (6) for cooling down, then send to storage tank (9) by pneumatic conveyor.

FIG. 4 shows a flow chart of an ammonium humate manufacturing process by solid-phase reaction. The process includes the steps below:

1. Feed humic acid to a mixer (3) by pneumatic conveyor (2) to premix the humic acid thoroughly.

2. Feed a fixed amount of the premixed humic acid into the solid-phase reactor (5) to agitate with a high speed mixer.

3. Spray a quantitative amount of ammonium hydroxide (12) uniformly into the reactor (5) using high-pressure air.

4. Continue high-speed agitation while proceed to complete mixing, reaction, and drying.

5. Recover ammonia and water vapor evaporated during reaction for recycling.

6. Unload ammonium humate salt produced into intermediate tank (6) for cooling down, then send to storage tank (9) by pneumatic conveyor.

EMBODIMENTS OF THE INVENTION

By employing a high-speed blender alone, the new process generates a vigorous powder flow and a series of unit operations (including crushing, mixing as well as dissolution, neutralization, and evaporation due to friction heat); the reaction temperature can thus be automatically controlled. The embodiments of this invention include, but is not limited, to the following:

1. A process for producing potassium humate with a solid-phase fluidized bed reaction. The mixture of potassium hydroxide containing 5 to 30% water and humic acid react in a high-speed intensive mixer running at 300-2000 RPM. The agitation is multidirectional and free flowing, and potassium humate is produced by means of high-speed agitation for mixing and neutralization reaction.

2. A process for producing sodium humate with a solid-phase fluidized bed reaction. The mixture of sodium hydroxide containing 5 to 30% water and humic acid react in high-speed intensive mixer running at 300-2000 RPM. The agitation is multi-directional and free flowing, and sodium humate is produced by means of high-speed agitation for mixing and neutralization reaction.

3. A process for producing potassium and sodium humate with a solid-phase fluidized bed reaction. The mixture of potassium hydroxide and sodium hydroxide containing 5 to 30% water and humic acid react in a high-speed intensive mixer running at 300-2000 RPM. The agitation is multi-directional and free flowing, and the mixture of sodium and potassium humate is produced by means of high-speed agitation for mixing and neutralization reaction.

4. A process for producing ammonium humate with a solid-phase fluidized bed reaction. This process uses a high-pressure spray mode to mix ammonium hydroxide with humic acid in a high-speed intensive mixer running at 300-2000 RPM. The agitation is multi-directional and free flowing, and ammonium humate is produced by means of high-speed agitation for mixing and neutralization reaction.

5. In accordance with Embodiments 1 to 4, a manufacturing process utilizes high-speed mixing to mix the mixture of solid containing less than 50% water and water-soluble solid or liquid-mist under fluidizing condition.

6. In accordance with Embodiment 5, the humic acid includes, but is not limit to, brown coal, peat, and weathering coal containing 5-90% humic acid.

7. In accordance with Embodiment 6, the raw materials of humic acid and caustic powder shattered by a mixer can increase the reaction area.

8. Use a high-intensity mixer to achieve uniform quality, while increasing the contact area of the base and reducing the solid-state reaction time.

9. Utilize high-speed stirring action to create sufficient heat by friction between reactant powders.

10. Utilize friction heat generated to liquefy solid alkali.

11. Potassium hydroxide is dissolved and ionized to K (or Na) ions which react with humic acid's COOH radicals ionized from humic acid.

12. Utilize the heat generated by the heat of reaction and friction heat to evaporate water and eliminate the energy required for drying.

13. Use the boiling point of water to make automatic temperature regulation.

Advantages Over the Prior Art

There are many unique technical advantages of the present invention over traditional methods of producing humic acid salts, such as those claimed by Patent CN101544675B. The most noticeable differences are:

1. This invention utilizes only high-speed agitation instead of the standard fluidized-bed, which requires a large amount of gas to fluidize the solid powder.

2. The present invention utilizes reaction heat and friction heat to evaporate excess water for keeping the reaction temperature and drying product simultaneously. The conventional method requires a lot of extra steam to maintain the reaction temperature.

3. The present invention is a dry process, achieving a complete reaction with very little additional water. On the contrary, the traditional method requires a lot of water to dissolve the caustic soda, before mixing with the humic acid to form a paste state, followed by more complicated steps.

4. In the present invention, the flow pattern is very vigorous by thoroughly mixing the solid ingredients to achieve a rapid reaction, which can be completed in less than 20 minutes vs. 20-26 hours claimed by Patent CN101544675B.

5. Technical specification of the basic principle behind the present invention is due to (a) the large contact area of the ingredients created by the high-speed mixing and (b) the neutralization reaction carried out both on the surface and on the inside of the powders. In the meantime, the temperature rises rapidly, causing the caustic flake to melt and then to penetrate into the humic acid powders by osmotic pressure.

6. This invention uses the frictional heat and exothermic heat generated by the reactants to control the reaction, to obtain more stable quality, and most importantly, to save a lot of energy from steam injection. Additionally, since all the chemical reactions take place under fluidizing conditions, any excess water contained in the mixture of solid phase (˜30% water) can be evaporated, thereby eliminating the subsequent product drying and grinding steps.

EXAMPLES

Three experimental tests were conducted under the setups in accordance with the concept described in this invention. Typical test conditions and the results obtained are shown in the following examples:

Example 1

-   -   Equipment: High speed intensive mixer (Henschel brand)     -   Capacity: 200-500 Liter Agitator speed: 500-1500 RPM     -   Recipe: Humic acid (Purity 44%, Water content 24%): 100 kg 90%         Potassium hydroxide: 13.3 kg (feed slowly)

Product Analysis:

Stirring Water Soluble Humic Time, min Content % Acid % 5 20.3 24.5 10 18.7 26.8 15 16.4 29.2 20 14.3 31.5 30 13.1 35.9

Example 2

-   -   Equipment: High speed intensive mixer     -   Capacity: 200-500 Liter Agitator speed: 500-1500 RPM     -   Recipe: Humic acid (Purity 44%, Water content 24%): 100 kg 72%         Sodium hydroxide: 12.6 kg (feed slowly)

Product Analysis:

Stirring Water Soluble Humic Time, min Content % Acid % 5 20.3 24.1 10 18.7 26.5 15 16.4 28.9 20 14.8 31.1 30 12.7 35.5

Example 3

-   -   Equipment: High speed intensive mixer     -   Capacity: 200-500 Liter Agitator speed: 500-1500 RPM     -   Recipe: Humic acid (Purity 44%, Water content 24%): 100 kg 35%         Ammonium hydroxide: 21 kg (under pressure spray mode)

Product Analysis:

Stirring Water Soluble Humic Time, min Content % Acid % 5 21.2 23.1 10 18.9 25.5 15 16.4 27.8 20 14.3 30.2 30 13.1 35.1 

1. A process for producing a dry humic acid salt, the process comprising: feeding a humic acid source into a reactor comprising a high-speed blender equipped with an agitator running at a speed sufficient to generate fluidizing conditions in the reactor; feeding solid alkali hydroxide into the reactor; mixing the humic acid source with the solid alkali hydroxide at conditions effective to melt the solid alkali hydroxide; reacting the melted alkali hydroxide with humic acid in the source to produce a humic acid salt; and drying the humic acid salt to obtain a dry humic acid salt, wherein the mixing, reacting, and drying take place in the reactor.
 2. The process according to claim 1, wherein the alkali hydroxide comprises potassium hydroxide, sodium hydroxide, or both.
 3. The process according to claim 2, wherein the humic acid salt comprises potassium humate, sodium humate, or both.
 4. The process according to claim 1, wherein the alkali hydroxide is introduced into the reactor in flake or powder form.
 5. The process according to claim 1, wherein the agitator generates sufficient frictional heat to liquefy the alkali hydroxide.
 6. The process according to claim 5, which comprises using the heat of reaction and the frictional heat to dry the humic acid salt.
 7. The process according to claim 1, which further comprises passing the dry humic acid salt to a cyclone separator.
 8. The process according to claim 1, wherein the humic acid source comprises brown coal, peat, or weathering coal.
 9. The process according to claim 1, wherein the reaction is completed in less than 20 minutes.
 10. A process for producing a dry ammonium humate, the process comprising: feeding a humic acid source into a reactor comprising a high-speed blender equipped with an agitator running at a speed sufficient to generate fluidizing conditions in the reactor; spraying ammonium hydroxide into the reactor; mixing the humic acid source with the ammonium hydroxide; reacting the ammonium hydroxide with humic acid in the source to produce ammonium humate; and drying the ammonium humate to obtain a dry ammonium humate, wherein the mixing, reacting, and drying take place in the reactor.
 11. The process according to claim 10, which comprises using the heat of reaction and the heat generated by friction to dry the ammonium humate.
 12. The process according to claim 10, which further comprises recovering ammonia and water vapor from the reactor.
 13. The process according to claim 10, which further comprises passing the dry ammonium humate to a cyclone separator.
 14. The process according to claim 10, wherein the humic acid source comprises brown coal, peat, or weathering coal.
 15. The process according to claim 10, wherein the reaction is completed in less than 20 minutes. 